Orthopedic device for unloading a knee

Abstract

An orthopedic device comprising a first shell, a second shell, and a hinge connecting to the first and second shells. A first strap having a first end slidably connects to the first shell and a second end removably anchors to the second shell. An overlay extends over a portion of the first shell and forms a clearance with the first shell into which the first end of the first strap extends. Portions of the overlay secure to the first shell outside of the clearance.

The invention claimed is: 
     
       1. An orthopedic device, comprising:
 a first shell; 
 a second shell; 
 a hinge connecting to the first and second shells; 
 a first strap having a first end slidably connected to the first shell and a second end removably anchored to the second shell; 
 an overlay extending over a portion of the first shell and is integrally secured therewith, the overlay forming a clearance with the first shell into which the first end of the first strap extends, portions of the overlay securing to the first shell outside of the clearance, the overlay forming a pocket with the first shell, and the clearance defining a distance from which a portion of the overlay extends outwardly away from the first shell to accommodate the first end of the first strap; and 
 a cable extending and confined between the overlay and the first shell, the cable connecting the first end of the first strap to a first tensioning mechanism, the first tensioning mechanism mounted directly onto the first shell and movable relative to the first shell to incrementally adjust a length of the first strap between the first and second shells, the cable extending through a guide covered by the overlay; 
 wherein the overlay is overmolded over at least an outer surface of the first shell and contoured to form a continuous surface without interruption with the first shell, the first shell defining a first shell body that is semi-rigid or rigid, and the overlay includes a peripheral edge extending about opposed inner and outer surfaces of first shell body and interlocking with a corresponding peripheral edge of the first shell body, the peripheral edge of the overlay is flexible; 
 wherein the first shell defines a first island along the outer surface about which the overlay surrounds and is devoid of the overlay, the first island encompassing the first tensioning mechanism and arranged offset to the clearance of the overlay; 
 wherein the pocket forms a transition that blends into and tapers in height relative to the first shell; 
 wherein the first shell has a hardness greater than a hardness of the overlay. 
 
     
     
       2. The orthopedic device of  claim 1 , wherein the overlay defines indicia indicating a length of the first strap between the first and second shells. 
     
     
       3. The orthopedic device of  claim 1 , further comprising a second strap having a first end slidably connecting to the first shell, and a second end removably anchoring to the second shell;
 a second tensioning mechanism mounted onto the second shell and movable relative to the second shell to incrementally adjust a length of the second strap between the first and second shells. 
 
     
     
       4. The orthopedic device of  claim 1 , wherein a first circumferential strap connects to opposed sides of the first shell, the first circumferential strap having a first end securing to the first shell and a second end releasably connecting to the first shell by a first connector. 
     
     
       5. The orthopedic device of  claim 1 , wherein at least one of the first shell and the second shell has a shell body defining a varying thickness along a length of the shell, defining at least one zone having a thinner thickness than in areas outside of the at least one zone. 
     
     
       6. The orthopedic device of  claim 5 , wherein the shell body has a varying thickness according to a height of the shell body, such that a thickness at a first portion of a height of the shell body at a location along the length of the shell body differs from a second portion of the height at the same location along the length. 
     
     
       7. The orthopedic device of  claim 1 , wherein the first shell defines a flaring contour extending generally outwardly toward a proximal end thereof and inclusive of the peripheral edge and a proximal end of the first shell body. 
     
     
       8. The orthopedic device of  claim 1 , wherein the peripheral edge has a first width at a first location, and a second width at a second location, the first width being greater than the second width. 
     
     
       9. The orthopedic device of  claim 1 , wherein the peripheral edge extends more over one side surface of the first shell body than another side surface of the first shell body. 
     
     
       10. The orthopedic device of  claim 1 , wherein the first and second shells are configured to contour about a cavity draw direction or about a user's leg, in at least three primary planes along the length of the first and second shell. 
     
     
       11. The orthopedic device of  claim 10 , wherein a first primary plane of the at least three primary planes is arranged generally posteriorly of an anterior-posterior plane of the orthopedic device, and/or a first strut or second strut connecting the hinge to the first and second shells, and defines a perforation region including at least one perforation. 
     
     
       12. The orthopedic device of  claim 10 , wherein a second primary plane of the at least three primary planes defines a slot for receiving a first strut or a second strut connecting the hinge to the first and second shells. 
     
     
       13. The orthopedic device of  claim 1 , wherein the overlay is a thermoplastic elastomer. 
     
     
       14. An orthopedic device, comprising:
 a first shell; 
 a second shell; 
 a hinge having first and second struts connecting to the first and second shells; 
 a first strap having a first end slidably connected to the first shell and a second end removably anchored to the second shell; and 
 an overlay extending over a portion of the first shell and is integrally secured therewith, the overlay forming a clearance with the first shell into which the first end of the first strap extends, portions of the overlay securing to the first shell outside of the clearance, the overlay forming a pocket with the first shell, the pocket configured to receive the first end of the first strap, and the clearance defining a distance from which a portion of the overlay extends outwardly away from the first shell to accommodate the first end of the first strap; 
 wherein the overlay is overmolded over at least an outer surface of the first shell and contoured to form a continuous surface without interruption with the first shell, the first shell defining a first shell body that is semi-rigid or rigid, and the overlay includes a peripheral edge extending about first and second opposed surfaces of first shell body and interlocking with a corresponding peripheral edge of the first shell body; 
 wherein the overlay is a thermoplastic elastomer and interlocks the first strut to the first shell; 
 wherein the first shell defines a first island along the outer surface about which the overlay surrounds and is devoid of the overlay. 
 
     
     
       15. An orthopedic device, comprising:
 a first shell; 
 a second shell; 
 a hinge having first and second struts connecting to the first and second shells; 
 a first strap having a first end slidably connected to the first shell and a second end removably anchored to the second shell; 
 an overlay extending over a portion of the first shell and is integrally secured therewith, the overlay forming a clearance with the first shell into which the first end of the first strap extends, portions of the overlay securing to the first shell outside of the clearance, the overlay forming a pocket with the first shell, and the clearance defining a distance from which a portion of the overlay extends outwardly away from the first shell to accommodate the first end of the first strap; and 
 a cable extending and confined between the overlay and the first shell, the cable connecting the first end of the first strap to a first tensioning mechanism, the first tensioning mechanism mounted directly onto the first shell and movable relative to the first shell to incrementally adjust a length of the first strap between the first and second shells, the cable extending through a guide covered by the overlay; 
 wherein the first shell defines a first island along the outer surface about which the overlay surrounds and is devoid of the overlay, the first island encompassing the first tensioning mechanism and being arranged between the first strut and the clearance; 
 wherein the overlay is overmolded over at least an outer surface of the first shell and contoured to form a continuous surface without interruption with the first shell, the first shell defining a first shell body that is semi-rigid or rigid, and the overlay includes a peripheral edge extending about first and second opposed surfaces of first shell body and interlocking with a corresponding peripheral edge of the first shell body. 
 
     
     
       16. The orthopedic device of  claim 15 , wherein the guide comprises at least one curved channel that extends between the first tensioning mechanism and the portion of the overlay that extends outwardly away from the first shell to accommodate the first end of the first strap.